Segmented Abrasive Wheel With Automatic Wear-Based Member Replacement

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Solution Overview

Problem

Existing methods for measuring abrasive member wear in grinding processes are prone to measurement errors due to substrate warpage and thickness variations, leading to inefficient manual replacement of entire abrasive wheels when the grit is worn out.

Innovation Solution

An abrasive wheel design with detachable abrasive members and a wear detector, allowing for independent replacement of worn abrasive members using electromagnets and a conveyor belt system to automate the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual replacement of the entire abrasive wheel is performed when the grit is worn out, then the grinding process can continue, but the operating time of the grinder is reduced and efficiency is lowered

Engineering Contradiction:

Improvegrinding efficiencyVSAvoidoperating time of grinder

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The abrasive wheel is divided into multiple independently replaceable abrasive members (130) that are detachably fixed to the holder (120). When one abrasive member wears out, only that specific member needs to be replaced rather than the entire wheel, thus minimizing downtime and maintaining high productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Worn abrasive members are automatically detached and collected by the collection assembly (240) while fresh members are supplied by the supply assembly (230). This automatic replacement system eliminates manual intervention and keeps the grinder operating continuously, maximizing productive time

Inventive Principle:

Principle #34Discarding and recovering

2Measurement precision

If measurement of abrasive member wear is performed based on descending distance of the grinding wheel, then wear can be monitored, but measurement errors occur due to substrate warpage and thickness variations

Engineering Contradiction:

Improvewear measurement accuracyVSAvoidmeasurement reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The wear detection system replaces mechanical measurement methods with optical sensors (260) that measure the actual physical dimensions of the abrasive members. This optical measurement system is not affected by substrate warpage or thickness variations, providing accurate and reliable wear detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of measuring wear indirectly through grinding depth, the system directly measures the physical state of the abrasive members using optical sensors. This direct measurement approach creates an accurate copy of the actual wear condition, eliminating errors from substrate variations

Inventive Principle:

Principle #26Copying

3Productivity

If the abrasive wheel is designed with detachable abrasive members and automatic replacement system, then replacement efficiency is increased and downtime is reduced, but the device complexity increases

Engineering Contradiction:

Improvereplacement efficiencyVSAvoidstructure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system is designed to automatically detect wear, supply new abrasive members, detach worn members, and collect them without any manual intervention. The electromagnets (124) automatically activate to attach/detach members, and the conveyor belt (210) automatically transports members between assemblies, making the system self-servicing and eliminating the need for operators to perform replacement tasks

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Multiple functions are merged into integrated assemblies: the supply assembly (230) combines member storage, conveyance, and positioning; the collection assembly (240) combines detachment, collection, and disposal functions; the holder (120) integrates electromagnets, seating portions, and support structures. This functional integration reduces overall system complexity while maintaining high automation

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables precise measurement and automatic replacement of worn abrasive members, enhancing grinding efficiency and reducing downtime by eliminating the need for manual intervention.

Implementation Method 1

a holder (120) fixed to the wheel body (110) and comprising a plurality of electromagnets (124), and a plurality of abrasive members (130) detachably fixed respectively to the plurality of electromagnets (124)

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentUS20250296201A1Abrasive wheel, abrasive member replacement device, and abrasive member replacement method

Publication Date: 2025.09.25 SAMSUNG ELECTRONICS CO LTD

AI summary

An abrasive wheel includes a wheel body configured to rotate about a rotary shaft, a holder fixed to the wheel body and comprising a plurality of electromagnets, and a plurality of abrasive members configured to grind a substrate, the plurality of abrasive members being detachably fixed respectively to the plurality of electromagnets, where each of the plurality of abrasive members is further configured to be independently replaceable.